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Intelligen - Version SuperPro - Designer Software - User Guide
SuperPro Designer®
User Guide
A Comprehensive Simulation Tool for the Design, Retrofit & Evaluation of Specialty
Chemical, Biochemical, Pharmaceutical, Consumer Product, Food, Agricultural,
Mineral Processing, Packaging
AND
Water Purification, Wastewater Treatment and Air Pollution Control Processes.
INTELLIGEN, INC. - 2326 Morse Avenue - Scotch Plains, NJ 07076 - USA
Tel: (908) 654-0088, (262) 483-8846, (609) 410-6484, Fax: (908) 654-3866
Email: info@intelligen.com Website: www.intelligen.com
Table of Contents i
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1 Getting Started
1.1 About This Manual .............................................................................................................. 1-2
1.2 Hardware & Software Requirements................................................................................... 1-3
1.3 Installation ........................................................................................................................... 1-4
1.4 Updates & Technical Support.............................................................................................. 1-5
1.4a Updating SuperPro Designer .................................................................................. 1-6
1.5 License Renewal.................................................................................................................. 1-7
1.5a License Renewal Using the Renewal//Dongle Application ..................................... 1-8
1.5b License Renewal Using SuperPro Designer in ‘License Renewal Mode’.............. 1-11
2 Tutorial
2.1 Developing a Process Model ............................................................................................... 2-5
2.1a Summary Steps ....................................................................................................... 2-6
2.1b Starting a New Process File .................................................................................... 2-7
2.1c Specifying the Mode of Operation for the Entire Plant .......................................... 2-8
2.1d Setting the Default Physical Units .......................................................................... 2-9
2.1e Registering Components and Mixtures................................................................... 2-9
2.1f Saving and Opening Files........................................................................................ 2-13
2.1g Building the Process Flowsheet .............................................................................. 2-13
2.1h Initializing Unit Procedures .................................................................................... 2-25
2.1i Switching Unit Procedures ...................................................................................... 2-43
2.1j Simulating the Process and Viewing the Simulation Results .................................. 2-44
2.1k Setting the Process Scheduling Information ........................................................... 2-51
2.1l Viewing Scheduling, Equipment Utilization and Resource Tracking Results ........ 2-53
2.1m Throughput Analysis and Debottlenecking ........................................................... 2-60
2.1n Cost Analysis and Economic Evaluation................................................................ 2-63
2.1o Environmental Impact............................................................................................. 2-72
2.2 The Synthetic Pharmaceutical Process ................................................................................ 2-73
2.2a Process Description................................................................................................. 2-74
2.2b Specifying Process Sections ................................................................................... 2-79
2.2c Specifying Equipment Sharing ............................................................................... 2-80
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2.2d Initialization of Reaction Operations ...................................................................... 2-82
2.2e Process Analysis ..................................................................................................... 2-84
2.2f Cost Analysis and Economic Evaluation ................................................................ 2-91
2.2g Environmental Impact............................................................................................. 2-92
2.3 The b-Galactosidase Process ............................................................................................... 2-92
2.3a Process Description................................................................................................. 2-93
2.3b Specifying Staggered Equipment............................................................................ 2-95
2.3c Initializing Data Specific to Biotech Processes ...................................................... 2-97
2.3d Specifying Storage Units ........................................................................................ 2-99
2.3e Process Analysis ..................................................................................................... 2-99
2.3f Cost Analysis and Economic Evaluation ................................................................ 2-103
2.3g Environmental Impact............................................................................................. 2-105
2.3h Product Formulation and Packaging....................................................................... 2-105
2.4 The Industrial Wastewater Treatment Process .................................................................... 2-106
2.4a Process Description................................................................................................. 2-106
2.4b Process Analysis ..................................................................................................... 2-113
2.4c Cost Analysis and Economic Evaluation ................................................................ 2-114
2.4d Modeling Challenges .............................................................................................. 2-117
2.5 Additional Information ........................................................................................................ 2-117
3 Components and Mixtures
3.1 Pure Components................................................................................................................. 3-1
3.1a Pure Component Registration ................................................................................. 3-2
3.1b Pure Component Registration Dialog ..................................................................... 3-5
3.1c Special Components................................................................................................ 3-11
3.1d Pre-Registered Components ................................................................................... 3-12
3.1e Pure Component Properties .................................................................................... 3-12
3.1f DIPPR Component Properties ................................................................................. 3-20
3.1g PPDS Component Properties .................................................................................. 3-21
3.1h Synchronize Registered Component Properties with Databank ............................. 3-21
3.1i Component Properties in a Binary Mixture............................................................. 3-22
3.2 Stock Mixtures..................................................................................................................... 3-23
3.2a Stock Mixture Registration ..................................................................................... 3-23
3.2b Stock Mixture Registration Dialog ......................................................................... 3-24
3.2c Pre-Registered Mixtures ......................................................................................... 3-28
3.2d Stock Mixture Properties ........................................................................................ 3-28
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3.2e Synchronize Registered Stock Mixture Properties with Databank......................... 3-30
3.3 Pollutant Categorization Guidelines .................................................................................... 3-31
4 Streams
4.1 Types of Streams ................................................................................................................. 4-1
4.2 Stream Drawing ................................................................................................................... 4-3
4.3 The Stream’s Context (or Command) Menu ....................................................................... 4-6
4.4 Stream Elbow Editing.......................................................................................................... 4-7
4.5 Stream Tags ......................................................................................................................... 4-8
4.5a Stream’s Name and Description Tag ...................................................................... 4-8
4.5b Stream’s Information Tag....................................................................................... 4-9
4.6 Stream Style......................................................................................................................... 4-10
4.7 Bulk Streams........................................................................................................................ 4-11
4.7a Viewing and Editing the Simulation Data of Bulk Streams ................................... 4-11
4.7b Composition & Related Properties of a Bulk Input Stream.................................... 4-12
4.7c Composition & Related Properties of Intermediate and Output Streams ............... 4-16
4.7d Stream Physical State Calculation Options ............................................................ 4-18
4.7e Stream Density Calculation Options....................................................................... 4-22
4.7f Environmental Properties of Bulk Streams ............................................................. 4-23
4.8 Discrete Streams .................................................................................................................. 4-24
4.8a Entity & Entity Properties....................................................................................... 4-24
4.8b Discrete Input Streams............................................................................................ 4-25
4.8c Viewing and Editing the Simulation Data of Discrete Streams.............................. 4-26
4.9 Auto-Initialization of Input Streams.................................................................................... 4-27
4.10 Classification of Input and Output Streams....................................................................... 4-27
5 Procedures & Operations
5.1 What Is a Unit Procedure?................................................................................................... 5-1
5.1a The Unit Procedure’s Context (or Command) Menu.............................................. 5-1
5.1b A Unit Procedure in a Batch Process...................................................................... 5-2
5.1c A Unit Procedure in a Continuous Process ............................................................. 5-3
5.1d Common Features ................................................................................................... 5-3
5.2 Unit Procedure Operating Mode.......................................................................................... 5-4
5.2a Holdup Time ........................................................................................................... 5-5
5.2b Procedure Cycle and Cycle Duration...................................................................... 5-6
5.3 Operation Sequence ............................................................................................................. 5-8
5.4 Unit Procedure Icon............................................................................................................. 5-11
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5.5 Unit Procedure Ports............................................................................................................ 5-12
5.5a Default Input Ports & Auto-Initialization ............................................................... 5-13
5.5b Default Output Port & Auto-Removal.................................................................... 5-14
5.6 Unit Procedure Labels ......................................................................................................... 5-14
5.7 Unit Procedure Icon Style.................................................................................................... 5-15
5.8 Unit Procedure Types .......................................................................................................... 5-16
5.9 Unit Procedure Families ...................................................................................................... 5-17
5.10 What Is a Unit Operation? ................................................................................................. 5-19
5.11 Tree-View of a Process...................................................................................................... 5-20
5.12 The Input//Output (i//o) Simulation Dialog ......................................................................... 5-21
5.12a The Labor Etc.Tab ................................................................................................ 5-22
5.12b The Description Tab ............................................................................................. 5-22
5.12c The Batch Sheet Tab ............................................................................................. 5-23
5.12d The Scheduling Tab .............................................................................................. 5-23
5.13 Procedure States................................................................................................................. 5-24
5.13a Procedure State Physical State Calculation Options............................................. 5-25
5.13b Procedure State Density Calculation Options....................................................... 5-30
5.14 Procedure PS and Density Calculation Default Options ................................................... 5-32
5.15 Default Data Values for Input Variables ........................................................................... 5-35
6 Resources
6.1 Main Equipment .................................................................................................................. 6-2
6.1a Sizing (Design vs Rating Mode) ............................................................................. 6-2
6.1b Selection & Sharing ................................................................................................ 6-3
6.1c Staggered Mode ...................................................................................................... 6-4
6.1d Contents .................................................................................................................. 6-5
6.1e Local Receptacle & Automatic Emptying of Contents........................................... 6-6
6.1f Purchase Cost .......................................................................................................... 6-6
6.1g Cost Adjustments .................................................................................................... 6-8
6.1h Consumables ........................................................................................................... 6-9
6.1i Allocation ................................................................................................................ 6-9
6.1j Suppliers, Specification Sheets & Specification Variables ..................................... 6-10
6.1k Type Categories ...................................................................................................... 6-10
6.2 Main Equipment Charts & Tables ....................................................................................... 6-11
6.2a Equipment Occupancy Chart .................................................................................. 6-11
6.2b Equipment Gantt Chart ........................................................................................... 6-13
6.2c Equipment Utilization Breakdown.......................................................................... 6-14
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6.2d Equipment Occupancy Data Table ......................................................................... 6-14
6.2e Equipment Occupancy Data Chart.......................................................................... 6-14
6.3 Auxiliary Equipment ........................................................................................................... 6-15
6.4 Auxiliary Equipment Charts & Tables ................................................................................ 6-17
6.4a Auxiliary Equipment Occupancy Chart .................................................................. 6-17
6.4b Auxiliary Equipment Gantt Chart........................................................................... 6-18
6.4c Auxiliary Equipment Demand ................................................................................ 6-18
6.4d Auxiliary Equipment Utilization Breakdown ......................................................... 6-18
6.5 Materials .............................................................................................................................. 6-19
6.5a Entering Material Consumption Classification....................................................... 6-19
6.5b Exiting Material Output Classification ................................................................... 6-20
6.5c Material Rates and Timing...................................................................................... 6-21
6.5d Material Inventory .................................................................................................. 6-21
6.5e Material Storage Units ............................................................................................ 6-22
6.6 Material Charts & Tables..................................................................................................... 6-22
6.6a Material Consumption & Material Output Charts .................................................. 6-22
6.6b Material Consumption Inventory & Material Output Inventory Charts ................. 6-24
6.6c Material Consumption (Demand) Tables................................................................ 6-25
6.6d Material Production (Output) Table ....................................................................... 6-25
6.7 Heat Transfer Agents........................................................................................................... 6-26
6.7a Definitions in the ‘System’ Database and in the ‘User’ Database .......................... 6-26
6.7b Registered (in use) Heat Transfer Agents............................................................... 6-26
6.7c Heat Transfer Agents in Sites ................................................................................. 6-27
6.7d Heat Transfer Agent Properties .............................................................................. 6-27
6.8 Heat Transfer Agent Charts & Tables ................................................................................. 6-28
6.8a Heat Transfer Agent Consumption Chart ............................................................... 6-28
6.8b Heat Transfer Agent Consumption Inventory Chart............................................... 6-29
6.8c Heat Transfer Agent Consumption (Demand) Table .............................................. 6-30
6.9 Power ................................................................................................................................... 6-30
6.9a Definitions in the ‘System’ Database and in the ‘User’ Database .......................... 6-31
6.9b Power Types Currently Consumed (or Produced) by the Process.......................... 6-31
6.9c Power Types in Database Sites ............................................................................... 6-31
6.9d Power Type Properties............................................................................................ 6-32
6.10 Power Charts & Tables...................................................................................................... 6-33
6.10a Power Demand & Power Generation Chart .......................................................... 6-33
6.10b Power Demand Table............................................................................................ 6-34
6.10c Power Production Table........................................................................................ 6-35
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6.11 Labor.................................................................................................................................. 6-35
6.11a Definitions in System DB and User DB ............................................................... 6-35
6.11b Labor Types Currently Used by the Process ........................................................ 6-35
6.11c Labor Types in Database Sites.............................................................................. 6-35
6.11d Labor Type Properties .......................................................................................... 6-36
6.12 Labor Charts & Tables....................................................................................................... 6-37
6.12a Labor Requirement Chart...................................................................................... 6-37
6.12b Labor Requirement (Demand) Tables .................................................................. 6-38
6.13 Material Storage Units....................................................................................................... 6-38
6.13a Registered (in use) Material Storage Units ........................................................... 6-40
6.13b Material Storage Unit Properties .......................................................................... 6-40
6.14 Material Storage Units Charts ........................................................................................... 6-41
6.14a Material Supply & Receiving Unit Rate Charts.................................................... 6-41
6.14b Material Supply & Receiving Inventory Charts ................................................... 6-42
6.14c Material Storage Unit Tables ................................................................................ 6-43
7 Scheduling
7.1 Scheduling Terms & Definitions ......................................................................................... 7-1
7.2 Scheduling Data................................................................................................................... 7-6
7.2a Operation-Level Scheduling Information ............................................................... 7-6
7.2b Procedure-Level Scheduling Information............................................................... 7-7
7.2c Recipe//Process-Level Scheduling Information....................................................... 7-8
7.3 Scheduling Calculations ...................................................................................................... 7-8
7.3a Scheduling Output Information .............................................................................. 7-9
7.3b Scheduling Constraints ........................................................................................... 7-10
7.3c Cycle Time Bounds Calculation ............................................................................. 7-11
7.3d Scheduling and Equipment Sizing .......................................................................... 7-11
7.4 The Operations Gantt Chart (OGC)..................................................................................... 7-12
7.4a Accessing Scheduling and Simulation Data ........................................................... 7-14
7.4b Exporting Chart & Data to Other Applications ...................................................... 7-14
7.4c Zooming // Time Scale............................................................................................. 7-15
7.4d Appearance (Visual Style) ...................................................................................... 7-16
7.5 The Equipment Gantt Chart (EGC) ..................................................................................... 7-16
7.6 The Equipment Occupancy Chart (EOC) ............................................................................ 7-16
8 Process Properties & Simulation
8.1 Sections & Branches............................................................................................................ 8-2
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8.1a Sections & Branches Toolbar ................................................................................. 8-3
8.1b Adding (Creating) a New Section........................................................................... 8-3
8.1c Adding Unit Procedures to a Section ...................................................................... 8-4
8.1d Section Properties ................................................................................................... 8-5
8.2 Branches .............................................................................................................................. 8-7
8.2a Adding (Creating) a New Branch ........................................................................... 8-8
8.2b Adding Sections to a Branch .................................................................................. 8-8
8.2c Branch Properties .................................................................................................... 8-8
8.3 Default Style for Process Elements ..................................................................................... 8-8
8.4 Physical Units Options ........................................................................................................ 8-11
8.5 Process Documentation (Description) ................................................................................. 8-11
8.6 Procedure & Equipment Order ............................................................................................ 8-12
8.6a Procedure Order ...................................................................................................... 8-12
8.6b Equipment Order..................................................................................................... 8-12
8.7 Drawing Size ....................................................................................................................... 8-13
8.8 Overview Navigator............................................................................................................. 8-14
8.9 Search and Locate Process Elements................................................................................... 8-15
8.10 Process Explorer ................................................................................................................ 8-16
8.11 The Stream Summary Table .............................................................................................. 8-18
8.12 Physical State Calculation Options.................................................................................... 8-20
8.12a The Shortcut Physical State Calculation Toolbox ................................................ 8-21
8.12b The Rigorous Physical State Calculation Toolbox ............................................... 8-22
8.12c Customizing the Physical State Calculation Options............................................ 8-22
8.13 Density Calculation Options.............................................................................................. 8-26
8.13a Liquid//Solid Phase Density Calculation Options.................................................. 8-26
8.13b Vapor Phase Density Calculation Options............................................................ 8-27
8.13c Customizing the Density Calculation Options...................................................... 8-27
8.14 The Process Simulation Engine ......................................................................................... 8-28
8.14a Simulation 101 ...................................................................................................... 8-28
8.14b Simplicity and the Art of Simulation .................................................................... 8-29
8.14c Simulation Philosophy .......................................................................................... 8-30
8.14d Process Operating Mode: Batch vs. Continuous .................................................. 8-34
8.14e Countdown to Simulation Execution: The Pre-Simulation Checks...................... 8-35
8.14f Partition & Sequencing.......................................................................................... 8-35
8.14g Loop Identification and Tear Stream Selection .................................................... 8-37
8.14h Convergence Strategy ........................................................................................... 8-39
8.14i Back-Propagation: Sources (Initiators) & Sinks (Terminals)................................ 8-42
8.15 Simulation Breakpoints ..................................................................................................... 8-46
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8.16 Simulation Control Toolbar............................................................................................... 8-49
8.17 Error Output Window........................................................................................................ 8-50
8.18 Other (Misc.) Process Properties ....................................................................................... 8-53
8.18a Show Page Breaks................................................................................................. 8-53
8.18b Report Scheduling Violations Only After M&E Balances ................................... 8-53
8.18c Always Perform Section Yield Calculations ........................................................ 8-53
8.18d Show Simulation Breakpoints .............................................................................. 8-53
8.18e Show Simulation Status Indicators for Each Procedure ....................................... 8-54
8.18f Update Simulation Status Indicators During M&E Balances ............................... 8-54
8.18g Slow Down Simulation Speed .............................................................................. 8-54
8.18h Apply External Auto-Initializations Upon Opening of Process File .................... 8-54
8.19 The Process File................................................................................................................. 8-54
8.19a Customizing Default Settings for a Domain of Applications ............................... 8-55
8.19b Working on a Long Term Project ......................................................................... 8-56
8.19c Automatic Versioning (Archiving) of the Process File ........................................ 8-57
8.19d Password Protected Process Files ......................................................................... 8-57
8.20 Application Settings........................................................................................................... 8-58
8.20a Announcements Upon Opening a Process File..................................................... 8-59
8.20b Automatic Background Saving of Modified Files ................................................ 8-59
8.20c Temporary Directory Location ............................................................................. 8-60
8.20d Startup Task .......................................................................................................... 8-60
8.20e Batch Sheet Forms Folder..................................................................................... 8-61
8.20f Workspace Appearance ......................................................................................... 8-61
8.20g Database Access UserID & Password .................................................................. 8-63
8.20h Automatic Procedure Name Generation ............................................................... 8-63
8.21 Auto-Initialization Links ................................................................................................... 8-64
9 Economics
9.1 Overview.............................................................................................................................. 9-1
9.2 Total Capital Investment...................................................................................................... 9-3
9.2a Direct Fixed Capital (DFC)..................................................................................... 9-3
9.2b Working Capital...................................................................................................... 9-10
9.2c Startup and Validation Cost .................................................................................... 9-10
9.2d Up-Front R&D Cost................................................................................................ 9-10
9.2e Up-Front Royalties.................................................................................................. 9-11
9.2f Capital Investment Charged to This Project............................................................ 9-11
9.3 Operating Cost ..................................................................................................................... 9-11
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9.3a Materials Cost ......................................................................................................... 9-12
9.3b Consumables Cost................................................................................................... 9-13
9.3c Labor-Dependent Cost ............................................................................................ 9-15
9.3d Utilities Cost ........................................................................................................... 9-17
9.3e Waste Treatment//Disposal Cost.............................................................................. 9-18
9.3f Facility-Dependent Cost .......................................................................................... 9-19
9.3g Laboratory // QC // QA Cost..................................................................................... 9-21
9.3h Transportation Cost................................................................................................. 9-22
9.3i Miscellaneous Operating Costs ............................................................................... 9-23
9.3j Advertising and Selling Costs ................................................................................. 9-23
9.3k Running Royalties................................................................................................... 9-24
9.3l Failed Product Disposal Cost................................................................................... 9-24
9.3m Cost of Heat Transfer Agents ................................................................................ 9-24
9.3n Unit Production//Processing Cost ............................................................................ 9-25
9.3o Depreciation............................................................................................................ 9-26
9.3p Net Annual Operating Cost..................................................................................... 9-28
9.3q Main Product//Revenue Rate ................................................................................... 9-29
9.3r Unit Reference Rate (or Flow) ................................................................................ 9-29
9.4 Income ................................................................................................................................. 9-30
9.4a Revenues ................................................................................................................. 9-30
9.4b Credits ..................................................................................................................... 9-32
9.4c Power Generation Procedures ................................................................................. 9-33
9.4d Savings.................................................................................................................... 9-34
9.5 Profits................................................................................................................................... 9-35
9.5a Profitability Analysis .............................................................................................. 9-35
9.5b Cash Flow Analysis ................................................................................................ 9-36
9.6 Energy Recovery ................................................................................................................. 9-42
9.7 Reporting of Economic Figures........................................................................................... 9-43
9.8 Currency .............................................................................................................................. 9-44
9.9 References............................................................................................................................ 9-45
10Emissions
10.1 Vent//Emission Calculations In Batch and Continuous Operations ................................... 10-2
10.1a Calculation of Vent//Emissions Methodology in Batch Processes ........................ 10-5
10.1b Calculation of Vent//Emissions Methodology in Continuous Processes............... 10-5
10.2 Special Emission Models For Wastewater Treatment Processes and Cooling Towers..... 10-6
10.2a Quiescent Tanks - Emission Model ...................................................................... 10-6
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10.2b Agitated Tanks - Emission Model ........................................................................ 10-9
10.3 Emission Calculations Based On EPA-MACT Guidelines ............................................... 10-13
10.3a Displacement Emissions Model............................................................................ 10-13
10.3b Depressurization Emissions Model ...................................................................... 10-14
10.3c Purging Emissions Model ..................................................................................... 10-16
10.3d Heating Emission Model ...................................................................................... 10-17
10.3e Gas Evolution - Emission Model .......................................................................... 10-20
10.4 Emissions Report (EMS) ................................................................................................... 10-20
10.5 EPA-MACT Emissions Report (EPA) .............................................................................. 10-20
10.6 Emission Limits ................................................................................................................. 10-21
11Debottlenecking
11.1 Definitions & Theory of Throughput Analysis ................................................................. 11-1
11.1a Identifying Equipment Time (Scheduling) Bottlenecks ....................................... 11-2
11.1b Identifying Equipment Size and Throughput Bottlenecks.................................... 11-2
11.1c Potential Maximum Throughput Size ................................................................... 11-5
11.1d Resource Bottlenecks............................................................................................ 11-6
11.1e Using Multiple Equipment Sets in Staggered Mode............................................. 11-7
11.2 Scale-up (or down) Process Throughput ........................................................................... 11-9
11.3 Throughput Analysis Report.............................................................................................. 11-11
12Reports
12.1 Generating and Viewing Reports....................................................................................... 12-2
12.2 General (Default) Reports Options.................................................................................... 12-4
12.3 Material & Stream Report (SR)......................................................................................... 12-7
12.4 Costing and Economic Evaluation Reports ....................................................................... 12-8
12.4a Economic Evaluation Report (EER) ..................................................................... 12-9
12.4b Cash Flow Analysis Report (CFR) ....................................................................... 12-13
12.4c Itemized Cost Report (ICR) .................................................................................. 12-15
12.5 Throughput Analysis Report (THR).................................................................................. 12-21
12.6 Environmental Reports ...................................................................................................... 12-22
12.6a Environmental Impact Report (EIR)..................................................................... 12-22
12.6b Emissions Report (EMS) ...................................................................................... 12-25
12.6c EPA-MACT Emissions Report (EPA).................................................................. 12-27
12.7 Equipment Report (EQR) .................................................................................................. 12-28
12.8 CIP & SIP Report (CSR) ................................................................................................... 12-29
12.9 Input Data Report (IDR).................................................................................................... 12-29
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12.10 Custom Excel Report ....................................................................................................... 12-31
12.11 Generate-and-Save A Report Set..................................................................................... 12-34
13Visual Objects
13.1 Types of Visual Objects..................................................................................................... 13-1
13.2 Adding a New Visual Object............................................................................................. 13-2
13.2a Text Object............................................................................................................ 13-3
13.2b Line ....................................................................................................................... 13-3
13.2c Rectangle, Round Rectangle or Ellipse................................................................. 13-4
13.2d Polyline or Polygon .............................................................................................. 13-4
13.3 Editing Existing Visual Objects......................................................................................... 13-5
13.4 Visual Objects Command Menu........................................................................................ 13-6
13.5 Visual Objects Toolbar ...................................................................................................... 13-8
13.6 Editing the Style of Visual Objects ................................................................................... 13-10
13.6a Editing the Default Style of Visual Objects.......................................................... 13-11
14Exchanging Data with Other Apps
14.1 Exporting Flowsheet & Chart Drawings ........................................................................... 14-2
14.1a Exporting Process Flowsheet Drawing ................................................................. 14-2
14.1b Exporting a Chart Drawing................................................................................... 14-6
14.2 Exporting Process Data...................................................................................................... 14-7
14.2a Export Process Scheduling Data to MS-Excel...................................................... 14-7
14.2b Export Resource Consumption Data to MS-Excel ............................................... 14-8
14.2c Exporting Scheduling & Resource Consumption Data to MS-Project ................. 14-9
14.2d Exporting Scheduling & Resource Consumption Data to SchedulePro ............... 14-10
14.3 Exporting // Linking Tables (Grids) to MS-Excel .............................................................. 14-12
14.4 Creating Hot-Linked MS-Excel Charts ............................................................................. 14-13
14.5 Importing OLE Objects ..................................................................................................... 14-14
14.6 Using SuperPro Designer’s OLE Server ........................................................................... 14-16
15Databases & Databanks
15.1 Database Registration ........................................................................................................ 15-3
15.2 Importing Data from Another ‘User’ Database ................................................................. 15-5
15.3 Accessing Data in Older ‘User’ Databases........................................................................ 15-6
15.4 Pure Components Databank .............................................................................................. 15-7
15.4a Viewing the Contents of the Pure Components Databank.................................... 15-7
15.4b Adding and Deleting Pure Components ............................................................... 15-8
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15.5 Databank of Stock Mixtures .............................................................................................. 15-8
15.5a Viewing the Contents of the Stock Mixtures Databank........................................ 15-8
15.5b Adding and Deleting Stock Mixtures ................................................................... 15-9
15.6 Binary Coefficients Databank............................................................................................ 15-9
15.6a Viewing the Contents of the Binary Coefficients Databank................................. 15-9
15.6b Adding and Deleting Binary Coefficients ............................................................ 15-10
15.7 Heat Transfer Agents Databank......................................................................................... 15-10
15.7a Viewing the Contents of the Heat Transfer Agents Databanks ............................ 15-10
15.7b Adding or Deleting a Heat Transfer Agent........................................................... 15-11
15.8 Power Types Databank ...................................................................................................... 15-11
15.8a Viewing the Contents of the Power Types Databank ........................................... 15-12
15.8b Adding or Deleting a Power Type ........................................................................ 15-12
15.9 Labor Types Databank....................................................................................................... 15-12
15.9a Viewing the Contents of the Labor Types Databank ............................................ 15-13
15.9b Adding or Deleting a Labor Type......................................................................... 15-13
15.10 Consumables Databank ................................................................................................... 15-14
15.10a Viewing the Contents of the Consumables Databank......................................... 15-14
15.10b Adding and Deleting a Consumable Type (Category)........................................ 15-14
15.10c Adding and Deleting a New Consumable........................................................... 15-15
15.11 Equipment Materials Databank ....................................................................................... 15-15
15.11a Viewing the Contents of the Equipment Materials Databank............................. 15-15
15.11b Adding and Deleting Equipment Materials ........................................................ 15-16
15.12 Currencies Databank........................................................................................................ 15-16
15.12a Viewing the Contents of the Currencies Databank............................................. 15-17
15.12b Adding and Deleting Currencies......................................................................... 15-17
15.13 Sites & Resources Databank............................................................................................ 15-17
15.13a Database Site (aka Database Facility)................................................................. 15-17
15.13b Viewing the Contents of the Sites Databank ...................................................... 15-19
15.13c Adding or Deleting a Site.................................................................................... 15-19
15.13d Adding, Deleting or Editing Database Resources .............................................. 15-20
15.14 Equipment Databanks...................................................................................................... 15-21
15.14a Site-Equipment Databank ................................................................................... 15-21
15.14b Equipment Spec Sheets Databank ...................................................................... 15-22
15.14c Equipment Suppliers Databank........................................................................... 15-23
15.14d Equipment Types & Specifications .................................................................... 15-24
15.14e Specification Variables Databank ....................................................................... 15-25
15.14f User Defined Cost Models Databank .................................................................. 15-26
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.C O N T E N T S
Table of Contents xiii
15.15 Processes Databank ......................................................................................................... 15-27
15.15a Adding a Process Record in the Processes Databank ......................................... 15-27
15.15b .Viewing the Process Records in the Processes Databank.................................. 15-27
15.15c Searching in the Processes Databank.................................................................. 15-28
INDEX
C O N T E N T S
xiv Table of Contents
Getting Started 1-1
. . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G ETTING S TARTED 1
elcome to Intelligen’s family of simulation software. Whether you acquired
SuperPro Designer or EnviroPro Designer you have now joined a large group of
professionals (engineers and scientists) from the industry and the academia who
have been using this software for over twenty five years in order to meet their every day
challenges in process simulation and related activities such as: process economics and
profitability assessment, retrofit and debottlenecking studies, environmental impact
assessment, emission reporting just to name a few. Here’s a partial list of companies that have
made our software part of their every day toolbox in order to meet their simulation challenges:
Amgen, Abbott Laboratories, ADM, Baxter, Bayer Technology Services (Europe and USA),
Biogen Idec, Bio-Rad Laboratories, Bio-Springer (France), Bristol-Myers Squibb, Cangene
(Canada), CDI, Centocor, CH2M Hill, Chugai Pharmaceuticals (Japan), CJ Corporation
(Korea), Colgate Palmolive, Crucell (Holland), CRB Engineers, Dow Chemical, DuPont, Eli
Lilly, Fluor, FMC BioPolymer, Foster Wheeler (UK), GE Healthcare, Genencor, Genentech,
Genmab (Denmark and USA), GlaxoSmithKline, Hitachi Plant (Japan), Hoffmann-La Roche
(multiple sites), Human Genome Sciences, Jacobs Engineering, Janssen (Belgium), Laporte
Consultants (Canada), Lonza (multiple sites), Medarex, MedImmune, Merck, Merck Serono
(Switzerland), Monsanto, NNE Pharmaplan (Europe), Novartis, Petrobras (Brazil), Pfizer,
Procter & Gamble, Regeneron, Roquette (France), SAIC-Frederick, Sandia National
Laboratories, Sanofi-Pasteur (Europe, Canada, and USA), Talecris Biotherapeutics, U.S. DOA,
DOD, DOE, Wyeth Pharmaceuticals. There are also over 300 universities worldwide that are
using this software for as part of their course curriculum (as a teaching aid) or for applied
research in the U.S. and abroad. For a more up-to-date list of industrial and academic users
please visit our web site (www.intelligen.com)..
The SuperPro//EnviroPro Designer software is today's best option for any chemical,
biochemical or environmental engineer and scientist in R&D, process engineering or
manufacturing. Whether you are a member of a biochemical, pharmaceutical, specialty
chemical, food company or whether you are employed by an environmental consulting firm or
a water purification//treatment plant, you can benefit from making this product part of your
every day computing options. Its use will enhance the productivity and communication efficacy
If you have purchased a copy of EnviroPro Designer please note that this manual was written
with a SuperPro Designer user in mind. You probably noticed that the cover page mentions
the name of SuperPro Designer right away instead of EnviroPro Designer. Please note that the
two products share an (almost) identical interface and make use of the same exact tools
(options) to tackle simulation and process evaluation issues. The main difference between the
two tools is simply the number of modeling modules available (options under the Unit
Procedures menu). EnviroPro Designer includes only a subset of the options that are available
for SuperPro Designer users. The subset of options included in EnviroPro Designer includes
modules most commonly needed to simulate processes in the water purification, wastewater
treatment and air pollution control areas.
W
G E T T I N G S TA RT E D
About This Manual
1-2 Getting Started
1
between all members in your group as well between your group and other groups of your
organization.
The SuperPro//EnviroPro Designer software manages a unique balance between flexibility, ease
of use and computational power. It can be readily used by a computer novice who is not
familiar with simulation and economic evaluation. At the same time, in the hands of a
simulation veteran, it can be used to model complex process situations under continuous or
batch mode or both (mixed mode processes). Both programs use the same user-friendly
interface, making it easy to migrate from one product to another as your needs may change in
the future. And in case you stumble across a question, help is just one keystroke away. Hitting
F1 will present a help screen that is closely related to the activity you are currently engaged.
Besides offering information on your current task, the help screen will also provide you with a
gateway into other (related) topics, all presented in an HTML format that should be already
familiar to all Windows users. The on-line help system also allows you to search for topics
related to keywords, jump from one help topic to another, and it is designed to help you ‘learn-
as-you-go’.
While we have made every effort to make the learning curve of our software as smooth and
short as possible, we also have loaded it with several features that will satisfy a simulation
veteran when it comes to carry out any of the following tasks:
• Material and Energy Balances of Integrated Processes
• Equipment Sizing
• Scheduling and Cycle Time Analysis of Batch Processes
• Cost Analysis and Economic Evaluation
• Throughput Analysis and Debottlenecking
• Environmental Impact Assessment
• EPA//MACT Compliant Report Generation
• COM Access for Programming Integration from VBA//C# Code.
All of the simulation results can be viewed in the form of either self-contained reports (in PDF,
Excel, Word, HTML and many other formats) or they can be included as part of your own
report put together in Excel. Using the latest OLE technology, you can also copy all or parts of
your flowsheet and//or any chart or other graph generated by the application and simply paste it
in your favorite Windows application used to put together your report or presentation.
1.1 ABOUT THIS MANUAL
Most users do not like reading manuals cover-to-cover. We understand that and therefore this
manual was put together with that in mind. However, as much as we have tried to make the use
of the software as easy and intuitive as possible, we believe that any user can benefit from
reading this manual (or at least specific topics). If you don’t have time to read the entire
manual, we strongly urge you to (at least) skim through the contents in order to get an idea
about the features of the software. As a minimum, please read through the first two chapters
and use the rest of the material just for reference. A comprehensive index at the end of the
printed manual can also help you locate the topic of your interest. Please note that the entire
. .
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.G E T T I N G S TA RT E D
Hardware & Software Requirements
Getting Started 1-3
contents of this manual, plus additional information regarding modeling details of all the
operation and equipment types supported by the software and more in-depth coverage of all the
interfaces (dialogs, charts, etc.,) are included in a PDF edition of the manual that is installed on
your PC (assuming you included the Help//Documentation component during installation). This
E-Book version of the manual is copied along with the program files under the user-selected
installation directory. The file’s name is “EBook.pdf”. A shortcut labeled accordingly has been
installed under the “SuperPro Designer” program group (under your “Start” button of your
desktop if your Windows version supports it). As any ‘pdf’ documents, it can be viewed
directly on your PC but it requires Adobe®’s Acrobat Reader® (v6 or later) to be present. If you
don’t have Adode®’s Acrobat Reader®, please visit http:////get.adobe.com//reader// and download
and install the latest version (free of charge).
In this chapter, you will find some general and useful information regarding the installation of
the software on your PC, see 1.3 Installation. Also, if you have purchased an annual license of
the software and you decide to extend your license for another term, you will find detailed
information on how to execute this procedure, see 1.5 License Renewal. Chapter 2 includes a
simple, step-by-step approach to what it takes to develop a process simulation using this
program. The end goal is to represent a very simple process as a vehicle in demonstrating the
principles and the most crucial elements of the user interface.
The Tutorial chapter (Ch. 2) includes three complete example simulations with more detail.
The first, deals with the production of ß-galactosidase (or b-gal) and is recommended for users
in the biochemical and related industries. The second, focuses on a synthetic pharmaceutical
process and it is recommended for users in the pharmaceutical, agrochemical, and specialty
chemical industries. The third, analyzes an industrial wastewater treatment plant, and is
recommended for users in the environmental field of applications. Regardless of which
example you chose, you will be presented with a comprehensive tour of most of the basic
features of the application and will have enough to get started with your own simulations.
1.2 HARDWARE & SOFTWARE REQUIREMENTS
SuperPro Designer will run on any modern PC running Windows Vista, Win7, Win8.x or
Win10 (32- or 64-bit). The application itself is (natively) a 32-bit application and if installed on
Please note that not all features of the software will be mentioned in the Tutorials included in
Chapter 2 of this manual. Users are strongly encouraged to experiment and explore for more
options available by reading the rest of the contents of this manual (or its E-Book equivalent),
or browsing through the on-line help system. Another option to become more familiar with all
the options available in SuperPro Designer and climb the learning curve in a fast pace is to
participate in one of our regularly scheduled training sessions taking place all over the world.
For details on upcoming dates and locations of Intelligen’s training sessions please visit our
web site ( www.intelligen.com//traning.html ). Another option to quickly become an expert user
may be possible to contact Intelligen, Inc. and arrange for an on-site training. On-site
training will bring our experts to your site and focus on your own organization’s simulation
needs and demonstrate to you how to meet them suing our software.
G E T T I N G S TA RT E D
Installation
1-4 Getting Started
1
a 64-bit Windows, it will run under the 32-bit compatibility mode (and thus will be installed
under the “Program Files (x86)” system area.
1.3 INSTALLATION
Most versions of SuperPro Designer require the use of a hardware security key in order for the
application to start and//or during its use. You do not need to plug in your sentinel key before
you start the installation process! In fact, you should not plug in the key until after the
conclusion of the installation. The presence of the key is not needed in order for the installation
to conclude successfully.
As soon as you insert the installation CD into your drive, the setup program will start
automatically. If the installation program doesn’t start automatically (an option on your
operating system may prevent this from happening) please right-click on your CD drive’s
image and start the installation program:
|‘SuperPro Designer vb.exe’ (e.g. “SuperPro Designer.v9.b04.exe”),
on the CD manually.
will be the major version number of the release you are installing (e.g. “9”,
“9.5” or “10”).
is the build number of the release you are installing (e.g. “02”, “05”, “12”, etc.)
For more details on the release number scheme for SuperPro Designer please consult the
“ReadMe” file.
The installation program will accomplish the following tasks:
1. It will personalize your copy of the application for your organization and yourself.
Hard Disk Space Depending on your choices during installation, the programs will
occupy anywhere from 350 MB (for minimum installation) to 550
MB of space on your hard disk. The size depends on whether you
chose to install all the example files and all files required for the on-
line (context-sensitive) help and documentation support.
Processor //RAM No special requirements needed over the minimum dictated by your
operating system.
Mouse The presence of a mouse or a similar pointing device supported by
your Windows operating system is required.
Video Adapter
& Monitor
No special requirements other than a minimum resolution of 1024 x
768 or better. A screen of 17” or better is strongly recommended for most comfortable use.
Printer Any printer or plotter supported by your Windows environment.If you don’t use a plotter and for best results a laser postscript printer
with at least 4MB of memory is recommended.
It is required that the application is installed by either a System Administrator or a user with
System Administrator privileges. Please contact your IT professional to inquire if your user
profile has such privileges. Also, please read through the relevant topics included in the
‘ReadMe’ file (located on the top-level of the installation CD) for more details regarding
installation, installation requirements, and troubleshooting problems during installation.
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.G E T T I N G S TA RT E D
Updates & Technical Support
Getting Started 1-5
2. It will copy all necessary files onto your hard disk at a directory of your choice.
3. It will make the necessary updates of your computer's registry.
4. It will create a program group with entries to run the application, its help system, the
license renewal utility, and the E-Book (full manual in pdf format).
During installation you will be asked to provide the following information:
(a) Your name and the name of your organization.
(b) A folder where the application will be installed.
(c) Another folder where the application’s database files will be installed.
(d) Which program configuration you want to install: Typical, Minimum or Custom. For
most users the default (‘Typical’) is recommended. Depending on your choice, different
sets of files will be copied. Custom installation will let you pick and choose what
components you need copied on your PC. Minimum installation will only copy the files
that are absolutely necessary for your program to run. It will not copy the help files and
the example files. If your hard disk space allows, it is highly recommended that you
install the help files as well as the example files. The examples contain several process
simulation files completed with the program, along with pertinent background
information for each case. If you decide not to include the examples during the first
installation, you can always run the setup program later and copy them to your hard disk
at that time. To avoid re-installing the entire program, the second time, select “Custom”
from the installation options, and pick only the “Example” component.
It is recommended that you review the ‘ReadMe’ file either at the conclusion of program
installation or at some other point before you start using your program for the first time. The
‘ReadMe’ file contains most important, up-to-date information about the release you have just
installed, including all the latest features that have been added and//or issues that may have been
addressed with that release.
1.4 UPDATES & TECHNICAL SUPPORT
Technical support is available for registered users with valid maintenance contracts. For users
who purchase perpetual licenses, you must make sure you keep your maintenance contract
active. This will entitle you for unlimited technical support should you have any questions
regarding the use of the software. Also, should you run into an unexpected program behavior,
Intelligen, Inc. will make every effort to resolve problem and issue a fix in a short time. Finally,
while your maintenance contract is active, you will receive, free of charge, any upgrades
released. It is very important that you complete the registration sheet (green form) that was sent
to you upon receipt of your original license or license renewal confirmation. After you fill up
The installation process will overwrite any files with the same name that may reside in the
specified installation folder except for the User DB. However, if you are performing a full
installation for a minor upgrade (with the same major version number) it is highly
recommended that you either make backup copies of your current user database file or specify
a new location for the DB installation to be safe.
G E T T I N G S TA RT E D
Updates & Technical Support
1-6 Getting Started
1
(or inspect and correct) the registration form please use the pre-stamped (for US destinations
only) envelope and mail it to:
Intelligen, Inc.
2326 Morse Ave.
Scotch Plains, NJ 07076
USA
If you have a valid maintenance contract and need to contact us for a technical support issue,
here are your choices:
1.4a Updating SuperPro Designer
If Intelligen, Inc. releases a new version for your software, you will be presented with an update
notification dialog. This dialog will inform you of the latest version available, provide you with
a quick link to browse all new features included in the new release and give you the option to
update the software.
Figure 1.1: Update Notification dialog
You can take the following actions:
• If you have latest credentials for accessing software downloads, click on the Download...
button. This will take you to the SuperPro Designer Download Center; when there, follow
instructions in order to download the latest version of your software edition (single-user,
site-license, academic, etc.).
E-Mail (preferred) TechSupport@intelligen.com
Phone (USA) (908) 654-0088, 9am-5pm EST
(262) 483-8846, 9am-5pm CT
Phone (Europe) (+30) (2310) 472-670, 9am-5pm in Europe (Greece).
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.G E T T I N G S TA RT E D
License Renewal
Getting Started 1-7
• If you do NOT have the latest credentials for access, click on the E-Mail... button. This will
open your default e-mail application with a preformatted e-mail addressed to Intelligen,
Inc. Technical Support (techsupport@intelligen.com). Fill in the blank areas and email the
notice to us. If you have an active maintenance, we will send you the new credentials you
need to gain access to the downloads. If you don’t have an active maintenance, we will
send you information on how to place an order to renew your maintenance.
• To view the new features in the latest release, click on the News... button. This will open
the “ReadMe” file of the latest release of the application. It contains all the new features,
improvements and corrections that are included in the latest release.
Normally, this upgrade notification dialog will be shown to you every time you start SuperPro
Designer. If you wish to not be notified until a week, or month passes, then please select the
corresponding option in the “Remind me again in” line, before you exit with OK.
1.5 LICENSE RENEWAL
If you are licensing this program for a limited time (typically a year) you will find out that after
the license expires, the program will give you few warnings and eventually will not start unless
you renew your license. The license renewal process is very simple and, in most cases, it can be
done from your own office. Before you start the license renewal procedure, you must purchase
an extension to your license and in return you will be given a password that is to be used during
the renewal process. Once you know your password, you are ready to start. The password is
only good for extending the license agreement for one term. The next time you need to extend
your license for another term, you have to repeat the process and acquire another password.
► To renew your l icense for another term. . .
There are two ways that you can initiate the license renewal process:
1. Run the ‘Sentinel Key (Dongle)’ application. This application should be available in the
same program group as SuperPro Designer, as it is installed along with SuperPro Designer,
when you first installed the software: If you can’t find the application’s entry to start it, you
can look into SuperPro Designer’s installation directory for an executable named
Before you initiate the license renewal process, please make sure that the time and date on
your PC are accurate. If you attempt to execute the renewal process with a date that is not
accurate, it is likely that the procedure will fail (either during the renewal process itself or
soon after you restart SuperPro Designer) leading to a possible lock-out of the key. Once a key
is locked out, then it is no longer usable. It must be returned to Intelligen, Inc. and a new key
programmed correctly for your new expiration date will be issued and sent to you.
G E T T I N G S TA RT E D
License Renewal
1-8 Getting Started
1
‘IntelligenKeyRenewal.exe’. You can either generate a shortcut on your desktop (and the
above icon will show), or simply double-click on it to run it. If you can’t find the above
executable in your SuperPro Designer’s installation folder, please get in touch with our
technical support team and we’ll let you know how to download it from our FTP site. For
further instructions on using the renewal application, see License Renewal Using the
Renewal//Dongle Application
2. You can start “SuperPro Designer” in a ‘License Renewal Mode’. To do that, you must
run the application from a command line. Start a command line in your Windows
environment (typically, this happens by selecting a “Run” command from the Start Menu).
Then from the Browse... button, navigate to the installation directory of SuperPro
Designer (typically C:\\Program Files (x86)\\Intelligen\\SuperPro Designer\\v) and select the “Designer.exe” file. This will copy the full name of the file in your
command line. Then type “//R” after the full name of the “Designer.exe” and click on OK.
For detailed instructions on how to proceed once you have started SuperPro Designer in
‘License Renewal Mode’, see License Renewal Using SuperPro Designer in ‘License
Renewal Mode’.
1.5a License Renewal Using the Renewal//Dongle Application
When you start the License Renewal (Dongle) Application the following dialog will appear:
This dialog presents fields with information in three groups:
(a) License Information Group
(b) Renewal Information Group and
(c) Company // License ID Group.
The License Information group’s field ‘Valid for’ will show one of four values:
- SuperPro Designer
- SchedulePro
- Intelligen Suite, or
- EnviroPro Designer
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.G E T T I N G S TA RT E D
License Renewal
Getting Started 1-9
Make sure you are receiving and applying a password appropriate for your application type and
duration shown after the ‘Valid for’ field.
The next group of fields (“Renewal Information”) presents information that is imprinted on
your dongle, and can be useful when requesting for a new password. First of all, the expiration
date is shown for your dongle. If you own a dongle for a perpetual license, this field will show
‘n//a’ (for non-applicable). If it’s a time-limited dongle, this field will show the date that the
active status of the dongle will expire. Please make arrangements to receive a password in time
before this date, in order to avoid interruption in your work as you will not be able to use the
software past its expiration date. In some rare cases, the password that you will be provided
may not match to the encrypted information on your key. In such cases, Intelligen’s tech
support team will ask you to provide the number shown in the field named “Template ID”. This
will help them supply to you the correct password for your dongle..
Once you receive by email a password sequence of characters, you should type it (or better yet,
copy-and-paste it to avoid mistakes) in the field highlighted in blue above, then click on the
Renew button that will become active once the sequence of characters matches an expected
pattern. As soon as you click on Renew, a dialog (like the one shown below) will popup to
verify that your PC currently reports the correct date, in the format mentioned in the dialog
(mo//day//year). Pay particular attention in the order between day and month. Once you have
confirmed that the date is valid, click on “Yes”. If the password you received matches the string
encrypted on your dongle, the following dialog will appear:
If instead a match has not been found, please try again taking extra care that your copy-and-
pasted password string is exactly what you were provided by Intelligen, Inc. (including any
Each dongle can only be renewed remotely (by executing this process) up to 6 times. After
that, the dongle is spent and it must be exchanged for a new one. That is why the last field in
this group presents the “Renewals Remaining” value. If this field shows 0, you cannot renew
your license remotely but instead, you must make arrangements to ship your old dongle to
Intelligen and you will receive a replacement already activated for your new license period.
G E T T I N G S TA RT E D
License Renewal
1-10 Getting Started
1
special characters such as ‘//’, ‘\\’ , ‘~’, ‘-’, etc.). If after repeating the process you still don’t see
the “Password match found!” announcement, please contact Intelligen. It is possible that your
dongle may have been damaged and passwords encrypted on it cannot be identified. This
typically happens if a dongle has been exposed to extreme temperatures, moisture or magnetic
fields (such as airport security scanners). In that case, Intelligen will ship a replacement key to
you in exchange for your old defective key that you must return (with a courier service) to
Intelligen. Assuming the password typed matches, you will then see this announcement:
If the new expiration date correctly matches your renewed license period, then confirm by
clicking on “Yes” to proceed. If the new expiration date has not been calculated as expected,
then click “No” to exit the renewal process and report the issue to Intelligen, Inc. Finally, once
you have confirmed the above date, the process will conclude with this announcement: This
concludes the renewal process. Notice that once the process concludes, you will now be shown
. .
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.G E T T I N G S TA RT E D
License Renewal
Getting Started 1-11
the initial interface (dialog) of the Renewal Application, only now some of the fields will be
updated to reflect current changes made:
Notice that the number of renewals remaining is now one less than what it used to be and that
the expiration date shown is the new date set by the renewal process.
1.5b License Renewal Using SuperPro Designer in ‘License Renewal Mode’.
Once you have started SuperPro Designer in ‘License Renewal Mode’, please follow the steps
below:
1. From the Help menu, please select Renew License.
G E T T I N G S TA RT E D
License Renewal
1-12 Getting Started
1
After you confirm that the reported time and date is correct (see notification window
below), the password entry dialog (see step 3) will appear.
2. When the password entry dialog appears, please type in the password that was provided to
you from Intelligen for this renewal process.
Please note that each password provided is only valid for one time. Also, the password is
likely to be a combination of numbers, letters (in upper or lower case) and hyphens (‘-’).
3. If the password string that was typed matches with the information imprinted on the
sentinel key, then the following message will appear:
If for some reason, a match was not found then you will see the following notification:
If you are certain that you provided the correct password yet the renewal process cannot
proceed beyond this point, please contact Intelligen, to resolve the issue. If we are unable to
resolve the issue, a new key will be shipped to you and you will be asked to send your old
key back.
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.G E T T I N G S TA RT E D
License Renewal
Getting Started 1-13
4. The next dialog will show you the date that will be used as the next expiration date imprint
on the key. If you agree, simply click OK. If you think that there has been an error in the
calculation of the next expiration date, please contact Intelligen. If you confirm the date
then after clicking OK, the license renewal process concludes announcing success!
NOTEs
1. The first time you attempt to start your program after your license agreement has expired
and you haven't renewed your license yet, a license violation will be detected and you will
be prompted to proceed with acquiring a password to start the license renewal process.
From that point on, you can only start the program again a few times before it locks itself.
Once the program locks itself, the only way to get it unlocked is to contact Intelligen, Inc.
and acquire a password in order to start the license renewal process described above.
2. You can only apply the above procedure on the same sentinel key for only a fixed number
of times (currently it is 6 times). After that, you will have to send your old hardware key to
Intelligen, Inc. in exchange for a new key that can be used for six more terms.
3. Although it is a rare case, it may be that your hardware key becomes defective and does not
respond to the above renewal procedure. If that case presents itself, then simply mail your
old key to Intelligen, Inc. and a new key will be sent out to you.
If you received the password electronically (via e-mail) it is recommended that you copy-and-
paste it from the original notification as it was sent to you from Intelligen, Inc. This way, you
will minimize the possibility of typographical errors which will lead to an unsuccessful
completion of the renewal process.
G E T T I N G S TA RT E D
License Renewal
1-14 Getting Started
1
Tutorial 2-1
. . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .T UTORIAL 2
n this chapter, we will guide you through the steps of creating a process model in
SuperPro Designer. We will first describe how to create a simple example process
model. This example will illustrate the key initialization steps involved with the
creation of any type of process. Regardless of which industry you are in, you should read
through this example to become familiar with the basic steps of modeling processes using
SuperPro Designer.
In addition to this simple example, three other process model examples will be described in this
chapter. These examples, listed below, are more complex than the first one and they are better
representations of what a “real” process modeled with SuperPro Designer would look like:
• Synthetic Pharmaceuticals. This example deals with a synthetic pharmaceutical process.
It is recommended for users in the pharmaceutical and specialty chemical industries.
• Biotech Processing. This example deals with the production of -galactosidase and it is
recommended for users in the bioprocessing industries.
• Wastewater Treatment. The third additional example deals with an industrial wastewater
treatment plant and it is recommended for users that target water purification and
wastewater treatment applications.
The table below provides a brief description of all the examples that are shipped with SuperPro
Designer and//or EnviroPro Designer (including those described in this chapter).
The sample simulation files are grouped into 6 domain folders based on their subject matter
(domain of application):
• Bio-Fuel Production
• Bio-Material Production
• Environmental Applications
• Food Processing
• Pharmaceuticals
Q: Where are the example models installed?
A: There are many sample models created with SuperPro Designer that installed with the
software. They come from a variety of domains (Pharmaceutical Production, Bio-Fuels, Food
Processing, etc.). All files are copied under the “Auxiliary Folder” that was provided during
installation of the software. By default, the “Auxiliary Folder” is located under:
C:\\Users\\Public\\Public Documents\\Intelligen\\SuperPro Designer\\v,
but it could have been set to some other location during installation.
Note that this is the same location where the database files and batch sheet templates are also
copied during installation.
I
T U T O R I A L
2-2 Tutorial
2
• Miscellaneous
• EPA // MACT Reporting Samples
• COM Engine Applications
Domain //
Folder Name
Available
in Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bio-Fuels //
AlgalOil
SuperPro
Designer
This example provides a basic representation of an
algae production and purification process that
generates a lipid which could subsequently be
converted into bio-diesel or jet fuel. It is
recommended for users with interests in biofuel
processes.
Bio-Fuels // BioDiesel SuperPro //EnviroPro
Designer
This example deals with the production of biodieselfrom soybean oil and it is based on a process model
developed by scientists at a research center of
USDA. It is recommended for users who areinterested in biofuel processes.
Bio-Fuels //
Ethanol
SuperPro Designer This example deals with the production of ethanolfrom corn stover. It can be readily modified to
represent conversion of other types of ligno-
cellulosic biomass into ethanol. It is recommendedfor people that are interested in production of
biofuels from renewable resources that do not
compete with food supplies.
Bio-Materials //
Bgal
SuperPro
//EnviroPro Designer
This example deals with the production of -
galactosidase. It is recommended for users in the
bioprocessing industries.
Bio-Materials // CitricAcid SuperPro Designer This example analyzes the production of citric acidvia fermentation. It is recommended for users with
interests in commodity biochemicals.
Bio-Materials // Lysine SuperPro Designer This example models a plant which produces 30,000metric tons of the amino acid lysine annually. Lysine
is produced industrially by microbial fermentation.
This example is recommended for users with interestin commodity biochemicals.
COM // Several SuperPro Designer This directory includes several examples of theCOM interface capabilities of SuperPro Designer
and EnviroPro Designer; for more details, see COM
Library.
Environmental //
AirContr
SuperPro
//EnviroPro Designer
This example analyzes a three-step process for
removing dust particles and acetone (a VOCmolecule) from an air stream. It is recommended for
users with interests in air pollution control
processes.
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. .
.T U T O R I A L
Tutorial 2-3
Environmental //
GE
SuperPro
//EnviroPro
Designer
This example analyzes an effort to minimize
generation of hazardous sludge and wastewater at a
manufacturing facility of General Electric. It is
recommended for users with interests in waste
minimization, water recycling, and pollution
control.
Environmental //
Incineration
SuperPro
//EnviroPro
Designer
This example describes a simple process (a single
unit) for analyzing the combustion of sludge in an
incinerator. It is recommended for users with
interests in incineration and pollution control.
Environmental // IndWater SuperPro //EnviroPro
Designer
This example deals with an industrial wastewatertreatment plant. It is recommended for users that
target water purification and wastewater
treatment applications.
Environmental //
MunWater
SuperPro
//EnviroPro Designer
This example focuses on the modeling and retrofit
design of a municipal wastewater treatment plant. Itaddresses issues of nutrient removal and it is
recommended for users with interests in industrial
and municipal wastewater treatment.
Environmental //
UPWater
SuperPro
//EnviroPro Designer
This example deals with water purification (ultra-
pure water production) and wastewater treatment at aSemiconductor Manufacturing Facility. Evaluation
of recycling options for minimizing city water use
and wastewater disposal is included. It isrecommended for users with interests in municipal
water purification and wastewater treatment.
EPA-MACT //
Several
SuperPro
Designer
This collection of examples demonstrates the ability
to put together a detailed EPA emissions report for a
processing facility. Emission data from several
processes are pulled together to a single Excel file.Aggregates for the month or year are also reported
utilizing batch records for the number of batches of
each recipe that was executed in a year.
Food Process //
Beet Sugar
SuperPro
Designer
This example simulates the production of sugar from
beets. There are several byproducts also (pulp,molasses, etc.) that provide additional revenue.
Food Process // Brewery SuperPro Designer This example simulates the operation of an industrialbeer production and packaging facility. It is
recommended for users in the brewing and beverage
industries.
Food Process //
Carageenan
SuperPro
Designer
This example captures the production of
Carrageenans from seaweed. Carrageenans arespecialty food ingredients produced in small
quantities around the globe.
Domain //
Folder Name
Available
in Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T U T O R I A L
2-4 Tutorial
2
Food Process //
Cheese
SuperPro
Designer
This example analyzes a highly integrated dairy
plant that produces cheese, butter, WPC, and ethanol.
It is recommended for users with interests in food
processing.
Food Process //
Corn
Refinery
SuperPro
Designer
This example captures a corn wet-milling process
integrated with the production of glucose and
fructose syrups.Corn is the most common cereal in
the U.S. Corn processing is key in the production of
biofuels, plastics, specialty chemicals etc.
Food Process //
Dextrose
SuperPro
Designer
This example presents the production of dextrose
crystals from glucose syrup 95%. Many corn refineryplants worldwide integrate the production of
dextrose.
Food Process //
Mannitol
SuperPro
Designer
This example demonstrates the production of
mannitol from 95% pure glucose syrup. Mannitol is
a sugar polyol with various applications in the foodindustries.
Food Process // O.J. Powder SuperPro //EnviroPro
Designer
This example analyzes a process for producingdehydrated orange juice powder. It is recommended
for users with interests in food processing.
Food Process //
Potato
Refinery
SuperPro
Designer
This example demonstrates a potato fractionation
process that yields multiple co-products. A simple
fractionation process typically coagulates theproteins of the potato juice and separates them for
use in the animal feed industry. The byproducts of
this process are protamylase ad fibers.
Food Process //
Sorbitol
SuperPro
Designer
The process presented here captures the production
of splay dried sorbitol. Sorbitol is a food andpharmaceutical ingredient produced in bulk
quantities around the world. It is a hydrogenated
glucose and, hence, sometimes called glucitol.
Food Process //
Sunflower
Oil
SuperPro
Designer
This is a simulation of a refined sunflower oil
production facility from sunflower seeds. Sunflower
oil is a popular vegetable oil frequently used forhome cooking but also it is found as an ingredient in
many other industrial products.
Food Process //
Xanthan
Gum
SuperPro
Designer
The production of xanthan gum from glucose by
means of fermentation is illustrated here. Xanthan
gum is a water-soluble thickening and stabilizingagent, widely used in the food, health care and oil
industries.
Pharma //
Insulin
SuperPro
Designer
This example analyzes the production of bio-
synthetic human insulin (a variation of Eli Lilly’s
process for Humulin). It is recommended for userswith interests in bioprocessing and
biopharmaceuticals.
Domain //
Folder Name
Available
in Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .
. .
.T U T O R I A L
Developing a Process Model
Tutorial 2-5
Since we are constantly adding and updating the sample files (examples) included with the
software, this list may not be reflect all the latest additions. For a more up-to-date listing please
consult the “ReadMe” file that came with your release of the software (under “Example
Process Files”). Each file (or sets of files) is accompanied with an MS-Word file that describes
the process in more detail.
2.1 DEVELOPING A PROCESS MODEL
The first example of this chapter demonstrates the key initialization and evaluation steps for
modeling a process with SuperPro Designer. The fundamental steps and analysis features used
in this example are the same as the steps and features that would be used during the creation of
any other type of process. Therefore, regardless of which type of process you intend to model,
reading through the following example should provide you with the basics needed to capture
and model any process (incl. your own). Since this example is a batch process, it serves as a
good medium for discussing several scheduling issues.
The following files are available for this example in the ‘Examples\\Misc’ directory of SuperPro
Designer ( is 10, 11, 12, ... matching the major version number of the release):
Pharma //
MAB
SuperPro
Designer
This example analyzes the production of a
therapeutic monoclonal antibody using animal cell
culture. It is recommended for users with interests in
animal cell culture and high value
biopharmaceuticals.
Pharma //
PharmTbl
SuperPro
Designer
This example deals with a process for making
pharmaceutical tablets. It is recommended for people
that deal with secondary manufacturing (dosage
formulation and fill-finish) of pharmaceuticals
and related products.
Pharma // SynPharm SuperPro //EnviroPro
Designer
This example deals with a synthetic pharmaceuticalprocess. It is recommended for users in the
pharmaceutical and specialty chemical
industries.
Pharma // Vial SuperPro
Designer
This example deals with a process that manufactures
5 mL lyophilized vials containing a therapeuticprotein. This example is recommended for users
interested in fill-finish steps.
Misc //
Several
SuperPro
//EnviroPro
Designer
This directory includes a number of small examples
that demonstrate key features of SuperPro Designer
such as special operations (Kinetic Reaction //Fermentation, Batch Distillation, etc.) or Inclusion of
Dynamic Charts that display concentration profiles
or liquid levels in a reactor, etc.
Domain //
Folder Name
Available
in Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T U T O R I A L
Developing a Process Model
2-6 Tutorial
2
1. GettingStarted_va: This file represents a simple batch process consisting
of a reaction step (Batch Vessel Procedure in a Reactor) and a filtration step (Plate and
Frame Filtration Procedure). The mass and energy balances for this process model are
solved with equipment in ‘Design Mode’ in order to have the simulation find their
appropriate sizes. The development and solution of this process model are described in
sections 2.1b Starting a New Process File up to 2.1i Switching Unit Procedures. The
specifications and analysis of scheduling, equipment utilization and resource tracking
information for this process model is described in sections 2.1k Setting the Process
Scheduling Information up to 2.1l Viewing Scheduling, Equipment Utilization and
Resource Tracking Results.
2. GettingStarted_vb: This process model is an evolution of the previous
model. The mass and energy balances are now solved for known equipment sizes, therefore
all equipment ‘Rating Mode’ in order to analyze the current and potential throughput and
economic assessment. A throughput and debottlenecking analysis for this process is
described in section 2.1m Throughput Analysis and Debottlenecking. Before any economic
assessment is made, economic data need to be supplied; their specification and analysis of
all the economics of the process is described in section 2.1n Cost Analysis and Economic
Evaluation.
2.1a Summary Steps
The steps listed below summarize the process of developing a model with SuperPro Designer.
These steps are explained in much greater detail in the remainder of this section (within
subsections 2.1b through 2.1o). Training videos which describe how to create models from
scratch can be found at http:////www.intelligen.com//videos.html. The Batch Process Tutorial
videos on this web-page correspond to the tutorial described in this chapter.
B R I E F O V E R V I E W O F T H E S T E P S I N V O L V E D I N M O D E L D E V E L O P M E N T A N D
A N A L Y S I S I N S U P E R P R O D E S I G N E R
1. Start a new process file by selecting ‘Start a New Process File’ in the opening dialog of the
program. Alternatively, you may start a new process file later by clicking on the New ( )
button on the Main toolbar or by selecting the File New from the menu of the program.
2. Slowly fill in more information to the process model by following the sequence of tasks
showing in the Tasks menu: (a) set the plant operation mode (batch or continuous) using
item Set Mode of Operation, (b) register in the model pure components using menu
item Pure Components Register, Edit//View Properties, register stock mixtures
using item Stock Mixtures Register, Edit//View Properties, and (c) if the plant
operation mode is batch, specify recipe scheduling information using item Recipe
Scheduling Information. If you prefer a certain set of physical units over others, you
may also want to visit the default physical units dialog now; it shown from Edit
Process Options Physical Units Options menu item.
3. Build the process flowsheet by adding unit procedures from the Unit Procedures menu
while in Select Mode ( ). Each unit procedure represents a small aggregate of actions,
For continuous processes, the steps that are related to the scheduling of operations within unit
procedures (see 2.1h Initializing Unit Procedures) and of the entire process (see 2.1k Setting
the Process Scheduling Information) can be skipped.
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.T U T O R I A L
Developing a Process Model
Tutorial 2-7
all executed in the same host equipment (e.g. a reactor vessel, or a chromatography
column). Switch to Connect Mode ( ) to draw streams representing material transfers
between unit procedures.
4. Add operations, such as Charge, Agitation, Batch Heating, Batch Stoichiometric Reaction,
etc., to each unit procedure. Different unit procedures have different operations available to
them. Batch//semi-continuous (cyclical) unit procedures can contain one or more
operations, whereas continuous unit procedures are equivalent to a single unit operation.
After the desired operations have been added, initialize all operations and streams.
5. Once you have included all operations that are necessary to represents the steps in your
process, you can complete the analysis of the process model using the following
commands: (a) solve mass and energy balances and size equipment by clicking Solve
M&E Balances ( ) on the Main toolbar or on the Tasks menu, (b) classify streams into
different categories (e.g., raw material, revenue, waste, etc.) using item Stream
Classification on the Tasks menu, and (c) perform costing and economic evaluation
calculations by clicking Perform Economic Calculations ( ) on the Main toolbar or
on the Tasks menu. Other analyses related to scheduling, throughput, and debottlenecking
may optionally be performed at this stage.
6. You can generate charts and visualize some of the results (outputs) of your simulation
model, using any of the commands in the Tasks, Charts and View menus. Finally, you
can generate and view reports using commands under the Reports menu.
2.1b Starting a Ne